C.D. Smith

When Green Bay Packaging Inc. – a Green Bay, Wis.- based manufacturer of high-quality products used for retail packaging and labeling applications – chose C.D. Smith to lay the foundation for its new 330,000-square-foot addition in summer 2013 – it knew it was getting the experts of concrete and steel.

The 78-year-old Fond du Lac, Wis.- based company is a general contractor that specializes in corporate structures, sustainable manufacturing plants, state-of-the-art healthcare facilities and educational buildings. 

“We are not just geared toward one or two markets,” Project Manager Jasen Anhalt says. “Our claim to fame was historically water treatment work, which we still do, but we have broadened our services.”

Today, C.D. Smith performs its services in the religious, municipal, education, healthcare, hospitality and commercial markets. Its annual revenue exceeds $300 million and C.D. Smith has become a well-known contractor in the Midwest by completing projects throughout Wisconsin and in nearly 20 states across the country. “We are a pretty well-rounded contractor, but our main bread and butter is in concrete and steel,” Anhalt adds. The company believes in delivering quality in every aspect of its operations and that dedication is exhibited in every one of its more than 400 employees. 

Perfect Packaging

C.D. Smith broke ground on a 31-acre, 330,000-square-foot building addition for Green Bay Packaging’s Coated Products Operations plant in July 2013. “Everything on this job is big,” Anhalt says. 

Inside the plant, Green Bay Packaging manufactures pressure-sensitive label materials, including a full line of coated papers, films, foils, direct thermal, thermal transfer, laser/ink jet, digital and specialty products. 

The addition to the plant will house new equipment from Germany to manufacture pressure-sensitive label stock. The addition will include a state-of-the-art automated storage and retrieval system (ASRS) in a separate building and a new pressure-sensitive coating line in the main building area, Anhalt explains. “The ASRS is interesting,” he adds. “The building is 600 feet long with multiple levels of racking. It’s all cranes and robotics that service this rack supported building by taking the pallets of paper rolls and placing them in specific rack locations.”

The main footprint of the addition is 500 feet wide by 404 feet long and a 28-foot-wide, 311-foot-long and three-story masonry structure will be constructed inside. This area will be separated from production and house office and lab space. “Their facility is very large and by adding this structure they will have a satellite office for the company,” Anhalt explains. “The existing facility houses the main headquarters.” 

Battling the Elements

The main challenge of the Green Bay Packaging project was the harsh winter. “This winter was terrible for everyone and obviously we couldn’t work all the time,” Anhalt says. “We didn’t plan to do concrete during the winter, but the design took longer than expected, so we first started pouring concrete in November and we just finished the bulk of the foundations [in March].” 

The design of the addition took longer than expected because a company in Germany is supplying Green Bay Packaging with its new technology. Anhalt says he has learned from this project to account for more time for designing when working with suppliers overseas. “Being in Germany, they are seven hours ahead of us and there is also a language barrier,” he adds.

C.D. Smith is self-performing the concrete foundations, precast and steel erection work, which is the bulk of the project. A number of precast steel erections and wall panels were manufactured because of the harsh weather. While performing its work, the company discovered alterations were needed due to poor soil conditions that contained a lot of groundwater, which is not conducive to supporting the weight of such a large structure, Anhalt explains. 

“The surface area didn’t support the foundation,” he adds. “We had to install aggregate piers for support. The ASRS is supported by 792 steel pipe piles that are driven 85 feet down to bedrock.” 

During peak construction, C.D. Smith has nearly 100 workers on site along with employees from Middleton Construction performing slab work, architects from Excel Engineering, mechanical and plumbing workers from August Winter & Sons, Inc., and fire sprinkler installers from Fireline Sprinkler Corp. A majority of the companies are based locally, Anhalt says. 

“The owner chose all local mechanical contractors and tried to use local contractors as much as they could,” he adds. “Given the size of the project, coordination has been key.” The construction portion of the Green Bay Packaging project is expected to be completed in October. 

 

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